Heater for an automotive vehicle and method of forming same

1. A heated seat comprising:

a seat with a cavity;

a heater overlaying the seat, the heater including:

i) a polymeric film flexible carrier having:

a. a longitudinal axis;

b. a first lengthwise edge;

c. a second lengthwise edge;

d. a width spanning between the first lengthwise edge and the second lengthwise edge,

e. a cutout in the first lengthwise edge and the second lengthwise edge that defines a narrow width region at a location corresponding with the cavity of the seat; and

f. a centralized through-hole opening in the narrow width region;

wherein the cutout in the first lengthwise edge and the second lengthwise edge each include indentations that define a concavity in the polymeric film;

iii) a first conductive medium disposed upon the carrier wherein the first conductive medium includes:

iv) a second conductive medium disposed on the carrier in an overlapping relation with the plurality of first extensions and the plurality of second extensions;

v) a first heating portion; and

vi) a second heating portion that is longitudinally spaced apart from the first heating portion and separated by the narrower width region;

wherein the narrower width region of the carrier is free of the plurality of first extensions, the plurality of second extensions, and the second conductive medium.

2. The heated seat as in claim 1 , wherein the only electrical connections of the heater are a first electrical connection and a second electrical connection, and

wherein the plurality of first extensions and the plurality of second extensions have a substantially continuous density throughout.

3. The heated seat as in claim 1 , wherein the plurality of first extensions have substantially the same shape and are substantially uniformly spaced apart from each other, and the plurality of second extensions are substantially uniformly spaced apart from each other.

4. The heated seat as in claim 1 , wherein the indentations include two pairs of opposing convex contours, one pair of opposing concave contours, and one central concave contour.

5. The heated seat as in claim 4 , wherein the polymeric film flexible carrier includes an adhesive that is disposed on either side of the carrier so that the adhesive adheres the heater to the seat.

6. The heated seat as in claim 5 , further including an electrical connection attached to and covered by a patch that is riveted to the base portion of the heater.

7. The heated seat as in claim 4 , wherein heater includes an insulating layer over the first conductive medium and the second conductive medium, the insulating layer being a film, a vinyl sheet, a flexible sheet, or the like.

8. The heated seat as in claim 4 , wherein heater includes an insulating layer being formed of fleece, gauze, or the like and fastened to the carrier by an adhesive.

9. The heated seat as in claim 1 , wherein the second conductive medium is a polymer thick film that is disposed over the first conductive medium.

10. The heated seat as in claim 1 , wherein the first lengthwise edge and the second lengthwise edge are spaced apart and generally parallel.

11. The heated seat as in claim 10 , further including one or more openings in the polymeric film flexible carrier.

12. The heated seat as in claim 11 , wherein the cavity trench and the narrower width region is adapted to extend at least partially into the trench.

13. The heated seat as in claim 12 , wherein the cutouts include two pairs of opposing convex contours, one pair of opposing concave contours, and one central concave contour.

14. The heated seat as in claim 1 , wherein the heated seat includes an occupancy sensor.

15. The heated seat as in claim 1 , wherein the centralized through-hole opening separates the polymeric film flexible carrier so that a carrier section is formed on one side of the centralized through-hole and a second carrier section is formed on a second side of the centralized through-hole.

16. A heated seat comprising:

a seat with a cavity;

a heater overlaying the seat, the heater including:

i) a polymeric film carrier including:

a) a longitudinal axis;

b) a peripheral edge that includes:

i. a first lengthwise edge, and

ii. a second lengthwise edge on an opposite side of the longitudinal axis, the second lengthwise edge opposing the first lengthwise edge, wherein each of the first lengthwise edge and the second lengthwise edge have a cutout with an indentation that includes two pairs of opposing convex contours, one pair of opposing concave contours, and one central contour;

c) a central through hole opening in the carrier that is located between the cutouts forming a narrow neck region that corresponds with the cavity of the seat;

d) one or more openings in the polymeric film flexible carrier;

e) a first conductive medium disposed upon the carrier wherein the first conductive medium includes:

1) a negative section having a plurality of first extensions; and

2) a positive section having a plurality of second extensions; and

f) a second conductive medium disposed on the carrier in an overlapping relation with the plurality of first extensions and the plurality of second extensions;

g) a first heating portion; and

h) a second heating portion that is longitudinally spaced apart from the first heating portion and separated by the narrower width region;

ii) an insulating layer over the first conductive medium and the second conductive medium, the insulating layer being a film, a vinyl sheet, a flexible sheet, or the like; wherein the narrower width region of the carrier is free of the plurality of first extensions, the plurality of second extensions, and the second conductive medium; and wherein the second conductive medium is a positive thermal coefficient material.

17. The heated seat of 16 , wherein heater includes an insulating layer over the first conductive medium and the second conductive medium, the insulating layer being a film, a vinyl sheet, a flexible sheet, or the like.

18. The heated seat of claim 17 , wherein the cavity is a trench and the narrower width region is adapted to extend into the trench.

19. The heated seat of claim 18 , wherein the negative section and the positive section are located on both sides of the longitudinal axis and are symmetrical in shape.

20. The heated seat of claim 16 , wherein the heater includes one or more electrical connections that are attached to the negative section and the positive section respectively by a rivet, and

wherein the one or more electrical connections are covered by a patch.